Retaining wall and method of making same

ABSTRACT

A retaining wall is provided that may include a first/bottom mat, a second/top mat and a third/cap mat. Each of the mats may include a plurality of elongated members connected to form a grid and may have a generally flat section. Each of the first and second mats may also include an upstanding section extending upwardly from a forward edge of the generally flat section. The upstanding sections may be inclined backwardly toward the generally flat sections. The upstanding section of the first mat may also include a plurality of extension members extending upwardly from an upper end of the upstanding section at an angle in relation to the upstanding section of the first mat, and be adapted for engagement with the second mat. The third mat may include a face section extending downwardly from a forward edge of the generally flat section of the third mat, which face section may be adapted for engagement with the upstanding section of the second mat, such as by means of a hook. One or more support members may be attached to the first and second mats to prevent the upstanding sections of the mats from bowing or inclining outwardly. Related methods are also provided.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention generally pertains to retaining walls, and moreparticularly to retaining walls made from grid-like components, and tomethods of making such retaining walls.

2. Description of the Related Art

It is known within a variety of fields to construct retaining walls forvarious purposes. Within the road construction industry, for example, itis known to erect temporary and permanent retaining walls forembankments, roadway supports, bridge abutments and the like. It is alsoknown that these retaining walls can be constructed using a variety oftechniques and materials, including, for example, concrete and/or weldedwire components. An example of a precast modular wall panel is disclosedin U.S. Pat. No. 5,259,704 to Ogorchock. Examples of retaining wallsconstructed using welded wire components may be found in a number ofU.S. patents, including, for example, U.S. Pat. Nos. 4,117,686 toHilfiker, 4,329,089 to Hilfiker et al., 4,391,557 to Hilfiker et al.,4,505,621 to Hilfiker et al., 4,856,939 to Hilfiker, and 5,722,799 toHilfiker. As will become apparent from the following description anddiscussion, however, the present invention, which is also directed toretaining walls that may be constructed with welded wire components,overcomes the deficiencies of the previous patents and constitutes animproved and more cost-effective retaining wall in comparison to thewalls and methods disclosed in the above-listed patents.

SUMMARY OF THE INVENTION

In one aspect, the present invention may be a retaining wall comprising:at least one first mat including a plurality of elongated membersconnected to form a grid, the at least one first mat having a generallyflat section and an upstanding section extending upwardly from a forwardedge of the generally flat section of the first mat, the upstandingsection of the first mat including a plurality of extension membersextending upwardly from an upper end of the upstanding section of thefirst mat at an angle in relation to the upstanding section of the firstmat; and a second mat including a plurality of elongated membersconnected to form a grid, the second mat having a generally flat sectionand an upstanding section extending upwardly from a forward edge of thegenerally flat section of the second mat, whereby the extension memberson the first mat are adapted for engagement with the second mat. Anotherfeature of this aspect of the invention may be that the wall may furtherinclude a third mat including a plurality of elongated members connectedto form a grid, the third mat having a generally flat section and a facesection extending downwardly from a forward edge of the generally flatsection of the third mat, whereby the face section is adapted forengagement with the upstanding section of the second mat. Anotherfeature of this aspect of the invention may be that the third mat mayfurther include at least one hook member adapted for engagement with anuppermost elongated member on the upstanding section of the second mat.Another feature of this aspect of the invention may be that each grid isformed of welded wires. Another feature of this aspect of the inventionmay be that the upstanding section of the first mat is inclined upwardlyfrom the generally flat section of the first mat when in a relaxedstate. Another feature of this aspect of the invention may be that theangle between the upstanding section of the first mat and the generallyflat section of the first mat is between approximately 75 and 80 degreeswhen in the relaxed state. Another feature of this aspect of theinvention may be that the upstanding section of the second mat isinclined upwardly from the generally flat section of the second mat whenin a relaxed state. Another feature of this aspect of the invention maybe that the angle between the upstanding section of the second mat andthe generally flat section of the second mat is between approximately 75and 80 degrees when in the relaxed state. Another feature of this aspectof the invention may be that the wall may further include at least onesupport member connected between one of the elongated members in theflat section of the first mat and one of the elongated members in theupstanding section of the first mat. Another feature of this aspect ofthe invention may be that the wall may further include at least onesupport member connected between one of the elongated members in theflat section of the second mat and one of the elongated members in theupstanding section of the second mat. Another feature of this aspect ofthe invention may be that the wall may further include a first sectionof filter material disposed adjacent a back surface of the upstandingsection of the first mat, and a second section of filter materialdisposed adjacent a back surface of the upstanding section of the secondmat. Another feature of this aspect of the invention may be that thewall may further include at least one face mat disposed adjacent a backsurface of at least one of the upstanding sections of the first andsecond mats. Another feature of this aspect of the invention may be thatthe wall may further include at least one section of filter materialplaced in one of a position between the face mat and the upstandingsection and a position behind and against the face mat.

In another aspect, the present invention may be a retaining wallcomprising: at least one first mat including a plurality of elongatedmembers connected to form a grid, the at least one first mat having agenerally flat section and an upstanding section extending upwardly froma forward edge of the generally flat section of the first mat, theupstanding section being backwardly inclined toward the generally flatsection when in a relaxed state, the upstanding section of the first matincluding a plurality of extension members extending upwardly from anupper end of the upstanding section of the first mat at an angle inrelation to the upstanding section of the first mat; and a second matincluding a plurality of elongated members connected to form a grid, thesecond mat having a generally flat section and an upstanding sectionextending upwardly from a forward edge of the generally flat section ofthe second mat, the upstanding section being backwardly inclined towardthe generally flat section when in a relaxed state, whereby theextension members on the first mat are adapted for engagement with thesecond mat. Another feature of this aspect of the invention may be thatthe wall may further include at least one support member attached to oneof the first and second mats and adapted to restrict the upstandingmember of the respective first or second mat from flexing past agenerally upright vertical position. Another feature of this aspect ofthe invention may be that the wall may further include a third matincluding a plurality of elongated members connected to form a grid, thethird mat having a generally flat section and a face section extendingdownwardly from a forward edge of the generally flat section of thethird mat, whereby the face section is adapted for engagement with theupstanding section of the second mat. Another feature of this aspect ofthe invention may be that the third mat further includes at least onehook member adapted for engagement with an uppermost elongated member onthe upstanding section of the second mat.

In still another aspect, the present invention may be a retaining wallcomprising: at least one first mat including a plurality of elongatedmembers connected to form a grid, the at least one first mat having agenerally flat section and an upstanding section extending upwardly froma forward edge of the generally flat section of the first mat, theupstanding section of the first mat including a plurality of extensionmembers extending upwardly from an upper end of the upstanding sectionof the first mat at an angle in relation to the upstanding section ofthe first mat; at least one first-mat support member connected betweenone of the elongated members in the flat section of the first mat andone of the elongated members in the upstanding section of the first mat;a second mat including a plurality of elongated members connected toform a grid, the second mat having a generally flat section and anupstanding section extending upwardly from a forward edge of thegenerally flat section of the second mat, the upstanding section beingbackwardly inclined toward the generally flat section when in a relaxedstate, whereby the extension members on the first mat are adapted forengagement with the second mat; and at least one second-mat supportmember connected between one of the elongated members in the flatsection of the second mat and one of the elongated members in theupstanding section of the second mat. Another feature of this aspect ofthe invention may be that the wall may further include a third matincluding a plurality of elongated members connected to form a grid, thethird mat having a generally flat section and a face section extendingdownwardly from a forward edge of the generally flat section of thethird mat, whereby the face section is adapted for engagement with theupstanding section of the second mat. Another feature of this aspect ofthe invention may be that the third mat further includes at least onehook member adapted for engagement with an uppermost elongated member onthe upstanding section of the second mat.

In yet another aspect, the present invention may be a method ofconstructing a retaining wall comprising: positioning a first mat on asurface, the first mat being constructed of a plurality of elongatedmembers connected in a grid-like fashion and having a generally flatsection and an upstanding section, the upstanding section of the firstmat including a plurality of generally straight extension membersextending upwardly from an upper end of the upstanding section of thefirst mat at an angle in relation to the upstanding section of the firstmat; positioning a first section of filter material adjacent a backsurface of the upstanding member of the first mat; positioning a portionof soil on the flat section of the first mat so as to hold the filtermaterial in place; positioning a second mat on top of the soil on thefirst mat, the second mat being constructed of a plurality of elongatedmembers connected in a grid-like fashion and having a generally flatsection and an upstanding section, and engaging the extension members onthe upstanding section of the first mat with the second mat. Anotherfeature of this aspect of the invention may be that the portion of soilon the flat section of the first mat has an upper surface substantiallyhorizontally level with the upper end of the upstanding section of thefirst mat. Another feature of this aspect of the invention may be thatthe upstanding section of the first mat is inclined backwardly towardthe generally flat section of the first mat when in a relaxed state, andis flexed forwardly to a generally upright vertical position when theportion of soil has been positioned on the flat section of the firstmat. Another feature of this aspect of the invention may be that thewall may further include connecting at least on support member to thefirst mat to restrict the upstanding section of the first mat fromextending away from the generally flat section of the first mat beyond agenerally upright vertical position.

Other features, aspects and advantages of the present invention willbecome apparent from the following discussion and detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded, perspective view of a specific embodiment ofwelded wire components that may be used to construct a retaining wall inaccordance with the present invention.

FIG. 2 is a side view of a specific embodiment of a first, or bottom,welded-wire mat of the type shown in FIG. 1.

FIG. 3 is a side view of a specific embodiment of a second, or top,welded-wire mat of the type shown in FIG. 1.

FIG. 4 is a side view of a specific embodiment of a third, or cap,welded-wire mat of the type shown in FIG. 1.

FIG. 5 is a side view of a specific embodiment of a first mat with aportion of soil or other fill materials placed thereon.

FIG. 6 is a side view as shown in FIG. 5 but with a filter materialadded and additional soil added so as to hold the filter material inplace.

FIG. 7 is a side view showing a mat being placed on top of the mat andsoil shown in FIG. 6.

FIG. 8 is a perspective view illustrating the use of a face mat placedbehind and against an upstanding section of a mat.

While the invention will be described in connection with the preferredembodiments, it will be understood that it is not intended to limit theinvention to those embodiments. On the contrary, it is intended to coverall alternatives, modifications, and equivalents as may be includedwithin the spirit and scope of the invention as defined by the appendedclaims.

DETAILED DESCRIPTION OF THE INVENTION

Referring to the drawings in detail, wherein like numerals denoteidentical elements throughout the several views, there is shown in FIG.1 an exploded, perspective view of specific embodiments of a group ofwelded wire components that may be used to construct a retaining wall inaccordance with the present invention. In a specific embodiment, thewelded wire components may include (1) at least one first, or bottom,mat 10, (2) a second, or top, mat 12, and (3) a third, or cap, mat 14.

With reference to FIG. 1, the at least one first mat 10 may include aplurality of elongated members 16 connected to form a grid. In aspecific embodiment, the grid may be formed of welded wires. The atleast one first mat 10 may include a generally flat section 18 and anupstanding section 20 extending upwardly from a forward edge 22 of thegenerally flat section 18 of the first mat 10. The upstanding section 20of the first mat 10 may include a plurality of generally straightextension members 24 extending upwardly from an upper end 26 of theupstanding section 20 of the first mat 10 at an angle in relation to theupstanding section 20 of the first mat 10, as best shown in FIG. 2,which is a side view of a specific embodiment of the first mat 10. Asalso shown in FIG. 2, in a specific embodiment, the upstanding section20 of the first mat 10 may extend upwardly from the generally flatsection 18 of the first mat 10 at an angle α in relation to thegenerally flat section 18 when in a relaxed, or un-flexed, state. In aspecific embodiment, the angle α may be in the range betweenapproximately 75 to 80 degrees.

As best shown in FIG. 1, the second mat 12 may include a plurality ofelongated members 16 (e.g., welded wires) connected to form a grid. Thesecond mat 12 may include a generally flat section 28 and an upstandingsection 30 extending upwardly from a forward edge 32 of the generallyflat section 28 of the second mat 12. As best shown in FIG. 3, which isa side view of the second mat 12, in a specific embodiment, theupstanding section 30 of the second mat 12 may extend upwardly from thegenerally flat section 28 of the second mat 12 at an angle β in relationto the generally flat section 28 when in a relaxed, or un-flexed, state.In a specific embodiment, the angle β may be in the range betweenapproximately 75 to 80 degrees. As will be more fully explained below,the extension members 24 on the first mat 10 are adapted for engagementwith the second mat 12 adjacent the forward edge 32 of the second mat 12when the retaining wall of the present invention is being constructed.

As best shown in FIG. 1, the third mat 14 may include a plurality ofelongated members 16 (e.g., welded wires) connected to form a grid. Thethird mat 14 may include a generally flat section 34 and a face section36 extending downwardly from a forward edge 38 of the generally flatsection 34 of the third mat 14. As best shown in FIG. 4, which is a sideview of the third/cap mat 14, in a specific embodiment, the face section36 may include one or more hook members 40 adapted for engagement withthe upstanding section 30 of the second mat 12, as will be more fullydiscussed below.

With reference to FIG. 3, in another specific embodiment, the second mat12 may further include one or more support members 42 connected betweenone of the wire members 16 on the generally flat section 28 of thesecond mat 12 and one of the wire members 16 on the upstanding section30 of the second mat 12. In a specific embodiment, each end of eachsupport member 42 may terminate in a hook so as to facilitate connectionof the support members 42 between the generally flat section 28 and theupstanding section 30. One or more support members 42 may also beconnected to the first mat 10 in the same manner as shown in FIG. 3 andexplained here with regard to the second mat 12. The support members 42may be sized so as to permit the upstanding section 20/30 to flexoutwardly, such as into a generally upright position when soil is placedonto the mats 10/12 and back-filled against the upstanding sections20/30, as more fully discussed below. In this manner, there may be someslack or range of movement when the support members 42 are initiallyattached. But when soil is back-filled on top of the mats 10/12 andagainst the upstanding sections 20/30, the connection between thesupport members 42 and the mats 10/12 will tighten up. The supportmembers 42 may be sized and positioned to as to prevent the upstandingsections 20/30 from bowing outwardly and/or inclining outwardly beyond agenerally upright vertical position.

As shown in FIG. 8, in another specific embodiment, a face mat 50 may bepositioned behind and against the upstanding section 20 of the first mat10. The face mat 50 may include a plurality of elongated members 16connected to form a grid, such as a grid of welded wires. The face mat50 may also include a plurality of extension members 52 along a loweredge of the face mat 50 to engage or interlock with the elongatedmembers 16 on the flat section 18 of the first mat 10. The face mat 50is preferably used to add strength when the above-described componentsare used to construct a permanent, as opposed to a temporary, wall.While the face mat 50 has been illustrated for use with the first mat10, it may also be used in the same way in conjunction with the secondmat 12. The filter material 46 may be positioned between the face mat 50and the upstanding sections 20/30, or behind and against the face mat 50in the same manner as explained above with regard to the upstandingsections 20/30.

The manner in which the above-described components may be used toconstruct a retaining wall, such as a temporary or permanent earth wallfor use in the road construction industry, will now be explained.

After the earth's surface on which the wall is to be placed has beengraded, a first mat 10 is placed on the graded surface. As shown in FIG.5, a portion of soil or other fill material 44 is placed over a rearwardportion of the generally flat section 18 of the first mat 10. In aspecific embodiment, the depth of the soil or other material 44 may beapproximately nine (9) inches deep. The soil 44 is preferably not placednear the upstanding section 20 at this time. As shown in FIG. 6, thismay be done so as to allow for placement of a filter material 46 (suchas a fabric material) adjacent a back side 21 of the upstanding member20. The filter material 46 is preferably folded to cover a portion of atop side 19 of the flat section 18 near the forward edge 22 thereof.Rolls of filter material 46 are shown in FIG. 1. If a face mat 50 is tobe used, it may be placed behind and against the upstanding section 20of the first mat 10 either before or after the filter material 46 isplaced into position. Additional soil or other fill material 48 is addedon top of the soil 44 and the first mat 10 and leveled off even with thetop of the upstanding section 20. The additional soil 48 is preferablyadded in layers of approximately nine inches in depth, and is alsopreferably compacted to approximately 95% compaction. The additionalsoil 48 is added so as to hold the filter material 46 against theupstanding section 20, and also in such a manner to preferably push, orflex, the upstanding section 20 into an approximately vertical, orgenerally upright, position (i.e., the upstanding section 20 is nolonger backwardly inclined and the angle α is now approximately ninety(90) degrees or thereabouts). One of the benefits of backwardly-inclinedupstanding sections 20/30 is that the likelihood that the upstandingsections 20/30 will bow, or incline, outwardly is reduced. For example,if every face section inclines outwardly just one inch, when this ismagnified over a number of layers of the wall the overall wall could beleaning outwardly by a distance of one foot or more. As discussed above,the use of support members 42 may also be used to prevent the upstandingsections 20/30 from inclining outwardly, such as beyond a generallyupright vertical position.

With reference to FIG. 7, depending on the overall desired height of theretaining wall to be constructed, the next step will be to either addanother first mat 10 or a second mat 12 on top of the structure shown inFIG. 6. In either event, when the next mat is added, it is positioned sothat the extension members 24 engage (e.g., by interlocking) with themat 10/12 being added at the forward edge 22/32 thereof. The processdescribed above of adding soil 44/48, filter material 46 and/or facemats 50 is continued until the top row is reached, at which time theprocess is again repeated with the second, or top, mat 12. The finalstep is to place the third, or cap, mat 14 over the soil on top of thetop mat 12, and then connect it to the second, or top, mat 12. In aspecific embodiment, the cap mat 14 may be connected to the top mat 12by engaging the one or more hooks 40 on the top mat 14 (see FIG. 4) withthe uppermost elongated member 16 on the upstanding section 30 of thetop mat 12. This process may be repeated any number of times dependingon the desired length of the retaining wall to be constructed.

It is to be understood that the invention is not limited to the exactdetails of construction, operation, exact materials or embodiments shownand described, as obvious modifications and equivalents will be apparentto one skilled in the art. Accordingly, the invention is therefore to belimited only by the scope of the appended claims.

1. A retaining wall comprising: at least one first mat including a plurality of elongated members connected to form a grid, the at least one first mat having a generally flat section and an upstanding section extending upwardly from a forward edge of the generally flat section of the first mat, the upstanding section of the first mat including a plurality of extension members extending upwardly from an upper end of the upstanding section of the first mat at an angle in relation to the upstanding section of the first mat; and a second mat including a plurality of elongated members connected to form a grid, the second mat having a generally flat section and an upstanding section extending upwardly from a forward edge of the generally flat section of the second mat, whereby the extension members on the first mat are adapted for engagement with the second mat.
 2. The retaining wall of claim 1, further including a third mat including a plurality of elongated members connected to form a grid, the third mat having a generally flat section and a face section extending downwardly from a forward edge of the generally flat section of the third mat, whereby the face section is adapted for engagement with the upstanding section of the second mat.
 3. The retaining wall of claim 2, wherein the third mat further includes at least one hook member adapted for engagement with an uppermost elongated member on the upstanding section of the second mat.
 4. The retaining wall of claim 1, wherein each grid is formed of welded wires.
 5. The retaining wall of claim 1, wherein the upstanding section of the first mat is inclined upwardly from the generally flat section of the first mat when in a relaxed state.
 6. The retaining wall of claim 5, wherein the angle between the upstanding section of the first mat and the generally flat section of the first mat is between approximately 75 and 80 degrees when in the relaxed state.
 7. The retaining wall of claim 1, wherein the upstanding section of the second mat is inclined upwardly from the generally flat section of the second mat when in a relaxed state.
 8. The retaining wall of claim 7, wherein the angle between the upstanding section of the second mat and the generally flat section of the second mat is between approximately 75 and 80 degrees when in the relaxed state.
 9. The retaining wall of claim 1, further including at least one support member connected between one of the elongated members in the flat section of the first mat and one of the elongated members in the upstanding section of the first mat.
 10. The retaining wall of claim 1, further including at least one support member connected between one of the elongated members in the flat section of the second mat and one of the elongated members in the upstanding section of the second mat.
 11. The retaining wall of claim 1, further including a first section of filter material disposed adjacent a back surface of the upstanding section of the first mat, and a second section of filter material disposed adjacent a back surface of the upstanding section of the second mat.
 12. The retaining wall of claim 1, further including at least one face mat disposed adjacent a back surface of at least one of the upstanding sections of the first and second mats.
 13. The retaining wall of claim 12, further including at least one section of filter material placed in one of a position between the face mat and the upstanding section and a position behind and against the face mat.
 13. A retaining wall comprising: at least one first mat including a plurality of elongated members connected to form a grid, the at least one first mat having a generally flat section and an upstanding section extending upwardly from a forward edge of the generally flat section of the first mat, the upstanding section being backwardly inclined toward the generally flat section when in a relaxed state, the upstanding section of the first mat including a plurality of extension members extending upwardly from an upper end of the upstanding section of the first mat at an angle in relation to the upstanding section of the first mat; and a second mat including a plurality of elongated members connected to form a grid, the second mat having a generally flat section and an upstanding section extending upwardly from a forward edge of the generally flat section of the second mat, the upstanding section being backwardly inclined toward the generally flat section when in a relaxed state, whereby the extension members on the first mat are adapted for engagement with the second mat.
 14. The retaining wall of claim 12, further including at least one support member attached to one of the first and second mats and adapted to restrict the upstanding member of the respective first or second mat from flexing past a generally upright vertical position.
 15. The retaining wall of claim 12, further including a third mat including a plurality of elongated members connected to form a grid, the third mat having a generally flat section and a face section extending downwardly from a forward edge of the generally flat section of the third mat, whereby the face section is adapted for engagement with the upstanding section of the second mat.
 16. The retaining wall of claim 14, wherein the third mat further includes at least one hook member adapted for engagement with an uppermost elongated member on the upstanding section of the second mat.
 17. A retaining wall comprising: at least one first mat including a plurality of elongated members connected to form a grid, the at least one first mat having a generally flat section and an upstanding section extending upwardly from a forward edge of the generally flat section of the first mat, the upstanding section of the first mat including a plurality of extension members extending upwardly from an upper end of the upstanding section of the first mat at an angle in relation to the upstanding section of the first mat; at least one first-mat support member connected between one of the elongated members in the flat section of the first mat and one of the elongated members in the upstanding section of the first mat; a second mat including a plurality of elongated members connected to form a grid, the second mat having a generally flat section and an upstanding section extending upwardly from a forward edge of the generally flat section of the second mat, the upstanding section being backwardly inclined toward the generally flat section when in a relaxed state, whereby the extension members on the first mat are adapted for engagement with the second mat; and at least one second-mat support member connected between one of the elongated members in the flat section of the second mat and one of the elongated members in the upstanding section of the second mat.
 18. The retaining wall of claim 16, further including a third mat including a plurality of elongated members connected to form a grid, the third mat having a generally flat section and a face section extending downwardly from a forward edge of the generally flat section of the third mat, whereby the face section is adapted for engagement with the upstanding section of the second mat.
 19. The retaining wall of claim 17, wherein the third mat further includes at least one hook member adapted for engagement with an uppermost elongated member on the upstanding section of the second mat.
 20. A method of constructing a retaining wall comprising: positioning a first mat on a surface, the first mat being constructed of a plurality of elongated members connected in a grid-like fashion and having a generally flat section and an upstanding section, the upstanding section of the first mat including a plurality of generally straight extension members extending upwardly from an upper end of the upstanding section of the first mat at an angle in relation to the upstanding section of the first mat; positioning a first section of filter material adjacent a back surface of the upstanding member of the first mat; positioning a portion of soil on the flat section of the first mat so as to hold the filter material in place; positioning a second mat on top of the soil on the first mat, the second mat being constructed of a plurality of elongated members connected in a grid-like fashion and having a generally flat section and an upstanding section, and engaging the extension members on the upstanding section of the first mat with the second mat.
 21. The retaining wall of claim 19, wherein the portion of soil on the flat section of the first mat has an upper surface substantially horizontally level with the upper end of the upstanding section of the first mat.
 22. The retaining wall of claim 19, wherein the upstanding section of the first mat is inclined backwardly toward the generally flat section of the first mat when in a relaxed state, and is flexed forwardly to a generally upright vertical position when the portion of soil has been positioned on the flat section of the first mat.
 23. The retaining wall of claim 19, further including connecting at least on support member to the first mat to restrict the upstanding section of the first mat from extending away from the generally flat section of the first mat beyond a generally upright vertical position. 